Bowflex Revolution Assembly Manual

The Bowflex Revolution

®

XP

Home Gym

Assembly Instructions

P/N: 001-7057 Rev $ (/0)

2

Before You Start ....................................... 2

Tools You Will Need / Hardware Contents .... 3

Box Contents ............................................ 6

Assembling Your Bowflex Revolution ..........10

Important Contact Numbers ......................29

Table of Contents

Before You Assemble

Select where you are going to locate your Bowflex Revolution®XP carefully. The best place for your

Bowflex Revolution®XP

is on a hard, level surface. For best results, assemble your the unit in the

location where you intend to use it. Allow a workout area of at least 7’ length x 7’ width (2.1m L x 2.1m

W) of free space for safe operation of the Bowflex Revolution®XP.

Basic Assembly Principles

Here are a few basic tips that will make your assembly of the Bowflex Revolution®XP quick and easy.

By using these principles, you can simplify each process and save yourself extra time and effort.

1. To make the assembly process go faster, gather the pieces you need for each step and thoroughly

read the assembly instructions for that step prior to starting assembly for the step.

2. When tightening a locknut on a bolt, use a combination wrench to grip the locknut and ensure that

it is fastened securely.

3. When attaching two pieces, gently lift and look through the bolt holes to help guide the bolt

through the holes.

4. As a general rule, and for all bolts and nuts on your Bowflex Revolution®XP, turn bolts or nuts

toward the right to tighten and left to loosen. Or you can remember the mnemonic: “Righty tighty,

lefty loosey.”

Before You Start

3

These Tools Are Not Provided in the Box

Phillips Head Screwdriver

3/4” and 9/16” Wrenches or Adjustable Wrenches

* Tool and Hardware specifications subject to change

without notice.

Hex Wrenches Are Provided in the Box

3/32” Allen Wrench for #8 Allen Screws

5/16” Allen Wrench for 1/2” Allen Screws

7/32” Allen Wrench for 3/8” Allen Screws

1/8” Allen Wrench for Top Cover Screws

3/16” Allen Wrench for Upholstery Screws

Tools You Will Need

Hardware Card (Box 2)

3

12

6

5

4

3

1

10

7

8

2

11

9

13

ITEM NO. QTY. DESCRIPTION

1 2 BUTTON HEAD CAP SCREW WITH THREADLOCK 3/8”X3/4”

2 2 NYLOCK NUT 1/2”

3 1 WRENCH, ALLEN HEX 3/32”

4 1 WRENCH, ALLEN HEX 1/8”

5 1 WRENCH, ALLEN 7/32”

6 1 WRENCH, ALLEN HEX 5/16”

7 2 WASHER 3/8”

8 4 WASHER 1/2”

9 5 SPRING CLIP

10 4 1/2” PLASTIC PLUG

11 4 3/8” PLASTIC PLUG

12 2 BUTTON HEAD CAP SCREW 1/2”x3 1/4”

13 1 WRENCH, HEX 3/16”

Hardware

3

4

2

6

5

3

2

1

8

6

9

11

10

12

7

2

3

Only two needed for XP model.

Use 4 for FT model.

Hardware

Hardware Card (Box 3)

ITEM NO. QTY. DESCRIPTION

1 6 BUTTON HEAD CAP SCREW 3/8”x 2 3/4”

2 16 NARROW WASHER 3/8”

3 7 NYLOCK NUT 3/8”

4 2 BUTTON HEAD CAP SCREW WITH THREADLOCK 3/8”x 3/4”

5 5 BUTTON HEAD CAP SCREW WITH THREADLOCK 1/2”x 1”

6 9 NARROW WASHER 1/2”

7 1 BUTTON HEAD CAP SCREW 3/8”x 4”

8 2 NYLOCK NUT 1/2”

9 1 BUTTON HEAD CAP SCREW 1/2”x 4 1/2”

10 2 RUBBER PAD

11 4 CABLE HOOK

12 1 BUTTON HEAD CAP SCREW 1/2”x 4”

Used on the FT model only

5

4

1

5

2

7

3

69

8

Hardware

Hardware Card (Box 4)

ITEM NO. QTY. DESCRIPTION

1 6 BUTTON HEAD CAP SCREW 3/8”x 4”

2 8 NARROW WASHER 5/16”

3 18 NARROW WASHER 3/8”

4 6 NYLOCK NUT 3/8”

5 8 BUTTON HEAD CAP SCREW WITH THREADLOCK 5/16”x 1”

6 1 SEAT BOTTOM LOCK PIN

7 6 BUTTON HEAD CAP SCREW WITH THREADLOCK 3/8”x 3/4”

8 1 LEG EXTENSION PIN

9 4 END CAP

6

Box Contents

4

5

6

2

3

1

Box 1 Contents

ITEM QTY. DESCRIPTION

1 1 PRE STRETCH HARDWARE PACK

2 4 20LB PACK ASSEMBLY

3 2 40LB PACK ASSEMBLY

4 2 PRE-STRETCH PACK ASSEMBLY

5 2 5LB PACK ASSEMBLY

6 2 10LB PACK ASSEMBLY

BOX 1

77

Box Contents

8

9

10

7

BOX 2

ITEM NO. QTY. DESCRIPTION

7 1 REVOLUTION MAIN UNIT

8 1 BOX HARDWARE CARD

9 2 FOOT CAP

10 1 REAR STABILIZER

Box 2 Contents

8

Box Contents

BOX 3

21

18

14

19

13

15

11

17

16

12

20

ITEM NO. QTY. DESCRIPTION

11 1 SHAFT

12 1 BOWFLEX HANDLE KIT

13 1 PLATFORM

14 1 LEFT STABILIZER

15 1 RIGHT STABILIZER

16 4 PULLEY

17 1 SQUAT HARNESS

18 1 MULTI POINT FOOT HARNESS

19 1 TRANSPORT WHEELS

20 2 LEG EXT CABLES

21 1 BOX 3 HARDWARE CARD

Box 3 Contents

9

24

30

32

23

22

26

25

27

28

29

31

33

34

35

ITEM NO. QTY. DESCRIPTION

22 1 SEAT TUBE

23 1 LOWER SEAT CONNECTOR

24 1 HARDWARE CARD BOX 4

25 1 LEG EXT ASSEMBLY

26 4 FOAM ROLLER PAD

27 2 ROLLER TUBE

28 1 SEAT TUBE CAP

29 1 DOCUMENTS KIT

30 1 BACK PAD

31 1 BACK PAD BRACKET

32 1 SEAT PAD BRACKET

33 1 SEAT PAD

34 1 RIGHT SEAT SUPPORT PLATE

35 1 LEFT SEAT SUPPORT PLATE

Box 4 Contents

Box Contents

BOX 4

10

Assembly (Unboxing)

Warning: The Bowflex Revolution

®

XP Home Gym is very heavy. Whenever possible use

two people to unbox the main unit.

We have designed the packaging to make unboxing the main unit as safe and easy as

possible.

Step 1

1-1

Open the top flaps of Box 2

(Figure A) and split the

corners along the perforations

to expose the top layer of

styrofoam. (Figure B)

Open top flaps

Split box corners

along perforations

Top layer of

styrofoam

Figure A

Figure B

Figure C

Figure D

Rear Stabilizer

Top layer of

styrofoam

Lower portion of

Main Frame

W ARNING

10

Rear Stabilizer Hardware

Figure E

Foot Caps

Step 2

2-1

Remove the Rear Stabilizer,

and Hardware Pack, (Figure C)

then remove the top layer of

styrofoam to expose the lower

portion of the Main Frame.

(Figure D)

The two Foot Caps that are

packaged in this box will be installed

in Step 6. (Figure E)

NOTE: Some of the hardware needed for unboxing is located on the Box 3 Hardware Card

11

Step 3 Assemble Rear Stabilizer

Parts:

• Rear Stabilizer (Box 2)

• Rubber Pads (Box 3 hardware card)

• Transport Wheels (Box 3)

Tools:

• 7/32” Allen Wrench

3-1 Insert Transport Wheels into Rear Stabilizer

making sure that the holes in the Stabilizer

and the plates on the Transport Wheels are

pointing up.

3-2 Install and completely tighten the hardware.

3-3 Press the Rubber Pads into the holes on the opposite

side of the hardware.

Rear Stabilizer

Hardware (1:1):

2 Button Head Cap Screw With Threadlock (3/8” X 3/4 ”)

2 Washer (3/8”)

Assembly (Unboxing)

Rubber Pad

Transport Wheel

Plate

Holes

Transport Wheel

Plate

12

Step 4 Install Rear Stabilizer

Parts:

• Rear Stabilizer (From Step 3)

Tools:

• 5/16” Allen Wrench

• 7/32” Allen Wrench

• 3/4” Wrench or Adjustable Wrench

4-1 Place the Rear Stabilizer in the bracket on the Main Frame with

the wheels pointing away from the frame. Make sure the two bolt

holes in the Rear Stabilizer are pointing downward.

4-2 Install but do not tighten two 3/8”x3/4” Allen Bolts and 3/8”

washers (Box 3 Hardware Card) in the underside of the Rear Stabilizer.

4-3 Install two 1/2”x3 1/4” Allen Bolts with 1/2” washers and Nylock Nuts

in the sides of the Rear Stabilizer.

4-4 Completely tighten all of the hardware.

Main Frame

Rear Stabilizer

Bracket

Wheels point

away from frame

Threaded bolt holes

point downward

Hardware (1:1):

2 Button Head Cap Screw (1/2” X 3 1/4”)

4 Washer (1/2”)

2 Washer (3/8”)

2 Nylock Nut (1/2”)

2 Button Head Cap Screw With Threadlock (3/8” X 3/4”)

1/2”x 3 1/4” Allen Bolt

1/2” Washer

1/2” Nylock Nut

3/8” Washer

3/8”x 3/4” Allen Bolt

Assembly (Unboxing)

13

Step 5 Install Stabilizers and Lower Lat Connector

Parts:

• Right and Left Stabilizer (Box 3)

• Lower Seat Connector (Box 4)

Tools:

• 5/16” Allen Wrench

• 3/4” Wrench or Adjustable Wrench

5-1 Insert Lower Seat Connector into the Main Frame with the

threaded hole on the flat side pointing down as shown.

5-2 Align the Right and Left Stabilizers with the holes in the Main frame.

5-3 Install but DO NOT TIGHTEN the hardware.

NOTE: You will install an additional screw in the Lower Seat Connector when the unit is upright.

Main Frame

Right Stabilizer

Hardware (1:1):

1 Button Head Cap Screw (1/2” X 4 1/2 ”)

6 Washer (1/2”)

1/2”x 1” Allen Bolt

1/2” Washer

Assembly (Unboxing)

1/2” x 4 1/2” Allen Bolt

1/2” Nylock Nut

1 Nylock Nut (1/2”)

Left Stabilizer

Lower Seat Connector

4 Button Head Cap Screw With Threadlock (1/2” X 1”)

Make sure threaded

hole is pointing down.

14

Step 6

Parts:

• Platform (Box 3)

• Foot Caps (Box 2)

Tools:

• 7/32” Allen Wrench

• 9/16” Wrench or Adjustable Wrench

6-1 Align Platform with Stabilizers making

sure the rubber pads are pointing

downward.

6-2 Install DO NOT TIGHTEN the hardware.

6-3 Install Foot Caps onto the ends of the Stabilizers.

Assembly (Unboxing)

Step 7

With the help of a partner, slowly roll the box completely over so the unit rests on the

Rear Stabilizer and Platform.

Hardware (1:1):

6 Button Head Cap Screw (3/8” X 2 3/4”)

12 Washer (3/8”)

3/8” Washer

3/8 x 2 3/4 ” Button Head

Cap Screw

6 Nylock Nut (3/8”)

3/8” Washer

3/8” Nylock Nut

15

Step 8

8-1 Lift the box up and off of the styrofoam packing.

8-2 Separate the styrofoam packing. Remove plastic

wrapping from the engine.

Lift box

Styrofoam packing

Separate styrofoam

packing

Step 9

Tools:

• 5/16” Allen Wrench

9-1 Install one 1/2”x3/4” Allen Bolt.

9-2 Make sure Platform is flat and level and

completely tighten hardware from steps 5

through 9.

Hardware (1:1):

1 Button Head Cap Screw With Threadlock (1/2” X 1 ”)

1 Washer (1/2”)

1/2”x 1” Allen Bolt

1/2” Washer

Assembly (Unboxing)

16

Top Cover

Remove screws

Step 10 Remove Top Cover

Tools:

• 1/8” Allen wrench

10-1 Use a 1/8” Allen Wrench to remove the four

screws in the Top Cover, then remove

the Top Cover and set it aside. Set screws

aside for Step 16.

Assembly

Styrofoam Packing

Remove front piece first

Step 11 Remove Styrofoam Inner Packing

11-1 Remove and discard the three pieces of

Styrofoam Inner Packing.

Note: You must open the plastic bag

and remove each piece of styrofoam

individually.

17

Step 12 Install Tension Shaft

Parts:

• Main Unit

• Shaft (Box 3)

12-1 Align the rounded side of the

Tension Shaft with the rounded

side of the hole in the Main Unit

and slowly slide the Shaft through

until it clicks into place.

If the Shaft is obstructed

inside the Main Unit,

loosen the tension

screws in the Tension

Shaft Holder (see Step 13).

Note: If you didn’t feel or hear a distinct click, make sure the shaft is centered by measuring the

amount of exposed shaft on each side of the Main Unit. There should be an equal measure

on each side.

Rounded edge on top

Shaft

Main unit

Assembly

18

Step 13 Tighten Tension Shaft Holder

Tools:

• 7/32” Allen Wrench

13-1 Use a 7/32” Allen Wrench to tighten the Tension Shaft Holder by

tightening the screws in numerical order shown on the tensioner.

Tighten the two screws marked 1, then the two marked 2, etc.

Note: Do not replace Top Cover at this time.

Tighten screws in order

1&1 , 2&2, 3&3, then

4&4.

Tension Shaft Holder

Tension screws

Assembly

19

Side view of pre-tension

SpiraFlex pack

Hooks toward

main unit

Pre-tension

SpiraFlex

®

Pack

Step 15 Remove Cam Holders.

Tools:

• Phillips Head Screwdriver

15-1 Use a Phillips Head Screwdriver

to remove the Cam Holders.

Note: The Cam Holders are only

needed when the Spiraflex

®

packs are not installed and

may be discarded or recycled.

Cam Holders

Allen Bolt

Remove Cam Holders

Cam

#8-32 X 3/8” Allen screw

®

Hardware (1:1): Hardware for this step located in Box 1

12 Allen Bolt ( # 8-32 X 3/8”)

Assembly

Step 14 Install Pre-Tension SpiraFlex® Packs.

Tools:

• 3/32” Allen Wrench (Box 1)

Parts:

• Pre-tension SpiraFlex

®

Packs (Box 1)

14-1 Align the rounded edge of the Pre-tension

SpiraFlex

®

Pack with the rounded edge of

the Tension Shaft and slide it all the way

onto the shaft.

14-2 When the Pack makes contact with

the Cam, continue to apply pressure

and twist the Pack to the left until

you feel the Pack seat into place.

14-3 Install and completely tighten

hardware, installing screws in a star

pattern around pre-tension pack.

20

Step 16 Replace Top Cover

Parts:

• Top Cover

Tools:

• 1/8” Allen Wrench

16-1 If the screws are still in the Top Cover

from Step 1, remove them to avoid

dropping them into the Main Unit.

16-2 Replace the Top Cover front end first.

Make sure inside edge of the Shroud

fits into the slots in the Top Cover.

Now seat the rear making sure the

tabs on the Top Cover fit inside the

Shroud.

16-3 Install and completely tighten the hardware.

Make sure inside edges

of Shroud fit in slots

on Top Cover

Inside Edge

Slots

Front

Rear

Top Cover

Tab

Shroud

Allen Screw

Assembly

Before Installing the Seat Support Plates (Step 17), make sure the Cables are properly tensioned

according to the following procedure . If there is slack in the Cables, the Support Plate Bolts

could cause interference.

Adjusting Cable Tension

Pay close attention to maintenance of the cable tension. Over time and with heavy use, the

cables are designed to give slightly. Located on the main engine housing is a tension control

knob which allows you to increase the tension in the cables.

Checking for incorrect cable tension is simple.

1. Position the adjustable swing arms in the upper most position.

2. Check to see if clips at end of cable hang down or if they are tight against the pulley.

3. If cables don’t have enough tension, use the tension control knob on the side of the machine to

tighten the cables. (See image).

4. To increase tension, pull tension knob outward and turn the large pulley clockwise. The clip on

the cable should be touching the pulley.

!44%.4)/.

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Bowflex Revolution, Revolution XP Assembly Manual

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